Pipe Insulation Support

Saddles

Proper mechanical support

is essential for a
smooth ride.
By Damien Cusick
Thermal piping systems require mechanical support in nearly every application, the lone exception
being direct burial piping applications. In almost all other applications, a hanger or other support
device is required to secure the pipe at its point of attachment to the structure that the piping is
crossing or servicing. The methods used to support thermal piping all seek to provide structural
rigidity to the system. Whether or not this comes at the expense of thermal efficiency is a critical
difference between the methods. We will examine some of the more common ways of dealing with
the issue of support and thermal efficiency at clevis hangers and roller support locations in thermal
piping systems.
TRADITIONAL SUPPORT METHODS

Insulated piping installed in clevis hangers in commercial applications is generally supported by a

pipe insulation protection shield (also known as saddles) of dimensions sufficient to keep the
insulation from being crushed in the support area. Originally slightly more than a half- cylinder of
sheet metal (see figure 1), these shields remain largely unchanged with a few notable exceptions
from certain manufacturers.
The shield's function is to distribute the load forces created by the loaded pipe (plus valves, flanges,
strainers or other items) and the insulation that exists between support locations over a larger
insulated surface area than would be present in the bare clevis hanger without a type 40 shield. The
support spans are usually governed by project specifications (or Manufacturers Standardization
Society Standard Practice [MSS SP-69, table 3 or table 5]). MSS SP-69 states accepted maximum
spans for assemblies using certain types of hangers, with spans as short as 6 feet for small bore
pipe, and as long as 20 feet for large bore pipe. Spans are often determined by the location and
availability of structural members to hang or attach a support. Because of this, they can vary from
the numbers in MSS SP-69 table 3 or 5 by a considerable margin.
In theory, the dimensions of type 40 shields or saddles are controlled by the MSS SP 58, Table 5, for
type 40 shields. MSS SP-58 is based upon protection of insulation having a compressive strength of
15 psi, which is a higher compressive strength than that of many common insulation materials.
Insulation types such as low density fiberglass and most elastomeric foams are "softer" than 15 psi.
The length and gauge of the shield (saddle) is determined by pipe size, not by insulated outer
diameter (see figure 1.1). To compensate for an insufficient shield length and insulation compressive
strength, the insulation materials will often receive inserts such as support plugs or blocks,
constructed of a high-density material such as wood. These plugs and blocks become the loadbearing components of most field-fabricated saddle assemblies for cold applications. They do
possess good load-bearing properties, but these items aren't efficient insulation materials. They
create a compromise between compressive strength and thermal performance. In reality, the
requirements for most projects fall short of the dimensional standards shown in MSS SP-58, table 5.
They're viewed by many as being in excess of what's actually necessary to provide proper
performance. Typically, only U.S. Army Corps of Engineers projects have strict standards resembling
the dimensions of MSS SP-58 table 5.
TREATMENT OF PIPING

Insulated piping installed on roller hangers or supports require a different treatment. It typically
receives a heavy duty weld-on shoe-type support saddle (MSS SP-58 type 39 or Grinnell figure 164 -

figure 166) to prevent crushing of the insulation in the roller contact area. (Grinnell [now Anvill]
product "figures" are commonly used in project drawings as detail items for clarification purposes.
They are common call-outs for mechanical contractors.) The insulation is generally butted against
this steel support and carefully worked around the legs to the greatest extent possible (see figure 2).
The metal-to-metal contact in the support area causes poor thermal performance and is impossible
to seal completely. It has undeniable structural superiority, but this comes at the expense of thermal
performance and condensation control.
Unchecked condensation will drip to surfaces below the support, lead to corrosion of the metallic
support components and ultimately contribute to premature component failure. Even when material
specifications call for wooden support saddles (Grinnell Figure 179 wood insulation saddle) on chilled
water lines, the thermal conductivity and condensation issues need to be addressed. Wood and steel
are fine building materials for structural purposes, but they offer less than reasonable insulation
value and thermal performance. They seem to be inherited from one project specification to the
next, allowing the problem to continue.
The metallic support items (type 40 shields and type 39 saddles) described so far are versatile and
non-specific as to temperature range. They're widely accepted for both hot and cold applications.
They leave the issue of insulation performance more to the installer, instead of the designer or
specifier. Some may argue that the total amount of piping subject to poor insulation performance
from traditional hanger treatments is insignificant. This isn't a valid argument if we're dealing with a
cold system. A small area subject to water vapor penetration will cause a large problem if left
unchecked. The best way to treat this problem is through a proactive materials selection process. By
being proactive, you can solve the problem with preventive action.
A basic division of intended applications should occur at this point: Is the application hot or cold?
Cold applications receive far more attention than do hot because of the obvious condensation
control issues on cold piping, versus visually undetectable heat loss issues on hot piping. A simple
high-density mass insulation insert (calcium silicate or perlite) in the support area is sufficient for
most hot piping applications. Heat loss in hot piping systems can have notable economic impact and
create personnel protection liability, but it still doesn't attract the attention that heat gain receives in
cold piping systems.
THE ROLE OF INSULATION COMPRESSIVE STRENGTH

The higher the compressive strength of the insulation, the shorter the support saddle has to be to
carry a particular load. A saddle supporting 50 psi compressive strength foam insulation in a clevis
hanger can be shorter in length than a saddle supporting 24 psi compressive strength foam
insulation. How much shorter depends on two factors; the specified support span (per MSS SP-69
and American Society for Testing and Materials [ASTM B31.1]) and the resulting load for the support
(span load). The span load is determined by the total weight of the pipe, filled with water, covered
with insulation and metal jacketing, per linear foot, multiplied by the footage between supports.
Additional loads such as valves and flanges must be added to the span load calculation. Of course,
smaller diameter pipes have lighter span loads than do larger diameter pipes. Safety factors can be
applied here as well, such as using schedule 80 pipe and 3 inch thick 14# pound per ft3 PCF density
insulation for all calculations. This is the baseline load number for the span.
The maximum load per type 40 saddle is based on the length of the saddle in inches, multiplied by
the compressive strength of the insulation in psi, times one-third of the insulated outer
circumference. This is usually a much greater value than the span load. The percentage difference
between the maximum load per saddle and the pan load is called a safety factor. Individual project
requirements vary widely, so no widely adopted uniform standard for insulation support saddles
exists. There have been numerous field expedients applied over the years, and many of these have
evolved into products developed out of requests from the field.
The previously mentioned calculations are necessary to perform if correct support is critical.
However, they can be left to those who manufacture insulated saddles and design each saddle for a
particular application and load range.

MODERN ALTERNATIVE SUPPORT METHODS: STARTING A PROACTIVE PROGRAM

Manufactured insulated saddles (also called pre-insulated saddles or insulated pipe supports) are
offered in response to the needs of designers, owners and installers seeking a better way to treat
the challenging conditions which exist at the pipe hangers and supports within any thermal system.
Traditional thermal insulation systems for piping have concentrated primarily on straight runs of
piping. Numerous thermal leaks were left at hanger and support locations because of a lack of welldesigned products to use at these locations. Trade-offs between compressive strength and thermal
performance in the saddle area are common with field-insulated saddles, but are eliminated with
manufactured insulated saddles.
With a variety of insulation types ideally suited for conditions within a particular temperature range,
insulated saddles offer the correct insulation for each application. Insulations for most cold
applications are 3# minimum density rigid polyisocyanurate (cellular glass can also cover this
temperature range, but it lacks significant compressive strength) for the wide range of temperatures
between minus 100 degrees Fahrenheit (F) and 250 degrees (F). High strength calcium silicate and
perlite are typically best for high-temperature applications from 250 degrees (F) through 1,200
degrees (F). Because it's a hydrous mass insulation, using calcium silicate on cold applications isn't
recommended. Attempts can be made to "waterproof" calcium silicate with silicones or other
compounds, but it remains a poor choice for below ambient applications due to its thermal
performance at this temperature range.
The support saddle often falls under the mechanical contractor's scope. It's also commonly included
in the insulation sub-contract. The insulator then has to fill in the saddles with support blocks,
insulation, mastic, and/or vapor barrier jacket. This is time consuming, to say the least. After these
steps are taken, the final fit and adjustment of the hanger is still the responsibility of the mechanical
contractor. The insulated saddle speeds up the total installation process for the insulation contractor
and thus accelerates the turnover and billing cycle, along with eliminating a notorious punch-list
item from the end of the job.
BENEFITS OF INSULATED SADDLES

Insulated saddles are a complete composite assembly, allowing for fast and simple installation. They
require significantly less labor to install than a field-assembled support system with separate
insulation, support inserts, vapor barrier and support saddle.
Insulated saddles save energy because they improve thermal performance by improving thermal
efficiency at hanger locations. Saddles for cold applications should have a 360-degree section of
properly selected high-performance foam insulation. This feature reduces operating costs for the
entire life of the thermal system. The insulation should feature a longitudinal lock-joint seam where
possible, to provide a longer offset thermal path to the cold pipe surface.
All cold service saddles should have a minimum 6 mil thickness film vapor retarder unless ASTM E84
compliance requires a laminated foil based all service jacket type barrier. This feature should
incorporate a self-sealing-lap. Selection of a high-performance vapor retarder reduces the likelihood
of condensation problems, and the damage to buildings that can result from condensate leakage.
The 180-degree steel saddle used to support the assembly should be flared at both ends to provide
maximum insulation (and vapor barrier) protection at all hanger locations and be constructed of
highest quality rust-resistant G-90 galvanized steel (or type 304 stainless steel alloy where required)
in 22 through 12 gauge thickness, depending on pipe size to provide positive hanger security and
aid in rapid installation.
Bare hangers with the notorious metal-to-metal contact problems, or improperly installed fieldinsulated shields and supports, can compromise the thermal integrity of an insulated piping system.
By leaving a large amount of under-insulated surface area, traditional methods and materials can
increase operating and maintenance costs over the lifetime of the system, especially on cold piping.
A properly selected insulated saddle will insure superior thermal performance at every hanger and
support location. In addition to increasing thermal performance, it also saves expensive labor by
reducing installation time. This is because every component is pre-assembled in its place and ready

to perform; for the most part, no additional materials such as staples or adhesives are required to
finish the job. No matter which trade jurisdiction the pipe saddles fall under, insulated saddles are
available for smart designers, owners and installers.
Insulated saddles allow insulation to pass uninterrupted through the support area on roller supports
for both hot and cold piping, creating a sealed thermal system where the traditional design (with the
weld-on shoe-type saddle shown in Figure 2 or wood type saddles) prevent this efficiency from
occurring. These saddles can carry a very high load in comparison to their weight, labor savings and
thermal efficiency. For this application, insulated saddles should always have a heavy gauge steel
(12 gauge minimum) support saddle, plus a structural steel support plate (1/4 inch thick minimum)
for 6 inch pipe and larger, to distribute the load from the pipe to the roller over the saddle area.
The user should contact the insulated saddle manufacturer to verify that the product choice is
appropriate for the application. Project specifications can sometimes be confusing, or even
inappropriate. Forwarding a copy of the job specification to the manufacturer is always a good idea if
the user has any questions.
This paper has discussed what can be inside a support location, what's probably inside a support
location and what should be inside a support location. Whether your applications are below ambient
temperature cold piping, such as chilled water or above ambient temperature such as steam piping
or condensate, there is an appropriate insulated saddle to fit your needs.
FIGURE 1.1

MSS-SP 58, Table 5, for type 40 shields.

Pipe Size (inches)

Shield Length (inches)

Saddle Gauge

.25 - 3.5

12

18

12

16

5-6

18

16

8 - 14

24

14

16 - 24

24

12

Table 5 is based upon 15 psi compressive strength insulation. For compressive strengths other than
15 psi dimensions may be adjusted accordingly.

This article appeared in the March 2002 issue of Insulation Outlook.

Author
Damien Cusick